Protective headgear assembly

ABSTRACT

The present invention generally relates to protective headgear worn by a user to protect his eyes, head, and face. More particularly, the present invention is directed to a protective headgear assembly used by welders and the like wherein a headgear strap can be tightened or loosened upon the ratcheting of a knob connected to the headgear strap. The headgear strap can also be automatically disengaged for removal of the headgear by pulling the knob away from the user&#39;s head.

RELATED APPLICATIONS

This is a continuation of co-pending U.S. patent application Ser. No.11/670,024 filed Feb. 1, 2007, entitled “Protective Headgear Assembly”.

FIELD OF THE INVENTION

The present invention generally relates to protective headgear worn by auser to protect his eyes, head, and face. More particularly, the presentinvention is directed to a protective headgear assembly used by welderswherein a headgear strap can be tightened or loosened upon theratcheting of a knob connected to the headgear strap. The headgear strapcan also be automatically loosened for removal of the headgear bypulling the knob away from the user's head.

BACKGROUND OF THE INVENTION

It has become commonplace for protective headgear to be worn while auser is undertaking a number of different activities. Frequently, thereare safety-related laws or standards that require certain types ofprotective headgear to be worn, depending on the occupation or activitya user performs. Different types of protective headgear are generallyknown in the art. Certain activities, such as welding, require thewearing of protective headgear, i.e., a welding helmet, to protect theuser's head, neck, face, and eyes. Other examples of protective headgearinclude bicycle helmets, motorcycle helmets, or helmets used duringsporting activities.

Protective headgear used for different purposes can differ greatly intheir design. Generally though, protective headgear will include: (1) aprotective body, i.e., a helmet, to cover the user's head, (2) a type ofheadgear strap attached to the helmet to enable the headgear to remainon the user's head during use, and (3) a suspension system to separatethe user's head from the helmet. Specifically with regard to welding,the user must also protect his eyes from dangerous sparks, heat,infrared and ultraviolet rays emitted when welding, while stillremaining able to see in front of him. Accordingly, the protectiveheadgear worn while welding further includes a face portion that acts toshield a user's face while allowing the user to see through the faceportion to view his work. In addition, protective headgear worn whilewelding should enable the user to pivot the helmet portion of theheadgear while the suspension system and headgear strap remain on theuser's head.

The headgear strap is typically adjustable to enable the user to changethe length of the strap to conform to the circumference of the user'shead. An adjustable headgear strap allows the protective headgear to fitcomfortably and securely during use, which is imperative duringdangerous practices such as welding. The strap can be of closed loopformation, or utilize a type of ratchet mechanism that enables thelength of the strap to be adjusted manually.

While ratchet mechanisms are generally known in the art and allow a userto manually loosen or tighten the headgear strap, none utilize a singlemechanism that can allow for both adjustment of the size and fit of theheadgear strap, and the ability to disengage the entire mechanism forautomatic loosening of the headgear strap so that the protectiveheadgear can be pulled off the user's head. Without a singlequick-release mechanism, it can often be awkward and take needless timeto ratchet the mechanism to loosen the headgear strap. Moreover, in theevent of a need to remove the protective headgear quickly, such as inthe event of an accident or other emergency, users, such as welders,should have a simple mechanism to free themselves of the oftentimesheavy and restrictive headgear.

There is a need to provide a protective headgear assembly with aheadgear strap that can be easily adjusted for length to enable a userto be able to wear the protective headgear assembly securely.

There is also a need for a protective headgear assembly that can beremoved in a simple, quick and efficient manner.

There is also a need for a protective headgear assembly wherein thehelmet can pivot from a closed position (during use) to an open position(when not in use) while the headgear strap and suspension system remainin place on the user's head.

Accordingly, it is desirable to provide a protective headgear assemblywherein the headgear strap can be both adjusted for length anddisengaged utilizing a single mechanism. By use of a single mechanism, auser can perform both actions in an easy and straightforward way.

It is also desirable to provide a protective headgear assembly whereinthe helmet is capable of pivoting from a closed position (during use) toan open position (when not in use) while the headgear strap andsuspension system remain in place on the user's head.

Thus, it is an object of the present invention to provide a protectiveheadgear assembly which effectively addresses the aforementionedshortcomings associated with prior apparatuses of this general type, aswell as to provide the above-mentioned desirable features.

SUMMARY OF THE INVENTION

The purpose and advantages of the present invention will be set forth inand apparent from the description that follows, as well as will belearned by practice of the invention. Additional advantages of theinvention will be realized and attained by methods and systemsparticularly pointed out in the written description and claims thereof,as well as from the appended drawings.

The present invention is generally embodied in a protective headgearassembly. The protective headgear assembly may be utilized for anyapplication wherein a user desires to protect his eyes, head and face.In particular, the present invention is directed to a protectiveheadgear assembly used to protect a user's eyes, head and face duringwork procedures. For example, the protective headgear assembly can beused by welders to protect the welders' eyes, head and face duringwelding procedures.

In accordance with one embodiment of the present invention, theprotective headgear assembly comprises a protective body, a headgearstrap, and a quick-release ratchet mechanism. In the preferredembodiment, the protective body is a helmet. It will be appreciated thatthe protective body can also be a face shield.

The quick-release mechanism of the present invention comprises a gearsystem and an adjusting knob. The headgear strap fits around thecircumference of a user's head in order to retain the protectiveheadgear apparatus securely on the user's head. The quick-releasemechanism is attached to the headgear strap and allows the user to: (1)manually adjust the length of the headgear strap, and (2) disengage thegear system in order for the user to automatically loosen the headgearstrap and quickly take the protective headgear assembly off of his head.Specifically, the knob can be ratcheted clockwise or counterclockwise toadjust the length of the headgear strap to ensure a secure fit on theuser's head. Turning the adjusting knob clockwise tightens the headgearstrap and locks it to a selected size. Turning the knob counterclockwiseloosens the headgear strap. In order for the user to disengage the gearsystem to unlock the selected size and allow for immediate headgearremoval, the knob can be pulled away from the user's head. The samepulling action away from the user's head also can loosen the headgearstrap to a selected size.

In another embodiment of the present invention, the protective headgearassembly further comprises an attaching assembly. In this embodiment,the helmet is attached to the headgear strap by means of attachingassemblies well known in the art, such as, e.g., as described in U.S.Pat. No. 4,479,738, the entire contents of which is hereby incorporatedby reference herein.

In another embodiment of the present invention, the helmet can beattached to the headgear strap by means of a side-pivot device. Theside-pivot device allows for the helmet to pivot from a closed position(during use) to an open position (when not in use) while the headgearstrap remains in place on the operator's head. The side-pivot devicelimits the range of motion through which the helmet can pivot and alsoprovides a positive dented stop at either end of the pivot path. Thepositive dented stops allow the helmet to rest in an open or closedposition until adjusted by the user. The side-pivot device isdistinctively a single piece that interacts with both the headgear strapand a pivot post that holds the device, strap and helmet together. Iteliminates the need for a separate locking bolt. In addition, theheadgear strap is able to accommodate the pivot device in two differentpositions. The positions move the helmet closer or farther from thefront of the operator's head. The functionality of the pivot remains thesame in either position.

In yet another embodiment of the present invention, the helmet can beattached to the headgear strap by means of a multi-position stopconstruction on a first side of the helmet and a detent cap constructionon a second side of the helmet. In this embodiment, a five-position stoppivots with the helmet. The five-position stop limits travel of thehelmet in both directions as it interacts with the headgear strap. Theclosed position (during use) of the helmet is determined by theinteraction between the five-position stop and a pin located on thehelmet. In the detent cap construction of this embodiment of the presentinvention, a washer key and detent cap interact and lock together tokeep the helmet locked in an open (not in use) position. The washer keyand detent cap are unlocked when the helmet is in the closed position.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and provided forpurposes of explanation only, and are not restrictive of the invention,as claimed. Further features and objects of the present invention willbecome more fully apparent in the following description of the preferredembodiments and from the appended claims.

The accompanying drawings, which are incorporated in and constitute partof this specification, are included to illustrate and provide a furtherunderstanding of the method and system of the invention. Together withthe description, the drawings serve to explain the principles of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

In describing the preferred embodiments, reference is made to theaccompanying drawing figures wherein like parts have like referencenumerals, and wherein:

FIG. 1 is a perspective view of the protective headgear assembly duringuse in accordance with the present invention;

FIG. 2 is an exploded perspective view of a quick-release mechanism madein accordance with the present invention;

FIG. 3 is a perspective view of the quick-release mechanism of FIG. 2;

FIG. 4 is a detailed view of the quick-release mechanism of FIG. 2,illustrating lateral movement of the overlapping ends of the headgearstrap caused by rotation of the adjusting knob;

FIG. 5 is a detailed view of the quick-release mechanism of FIG. 2,illustrating movement of the overlapping ends caused by counterclockwiserotation of the adjusting knob;

FIG. 6 is a perspective view of the quick-release mechanism of FIG. 2,illustrating movement of the adjusting knob and disengagement of thegear system caused by the pulling of the adjusting knob;

FIG. 7 is a cut-away perspective view of the adjusting knob of thequick-release mechanism of FIG. 2 when the adjusting knob is pulled,illustrating the disengagement of the gear system;

FIG. 8 is an exploded perspective view of the multi-position stopconstruction made in accordance with the present invention;

FIG. 9 is a perspective view of the protective headgear assemblyillustrating the five-position stop engaged with the pin affixed to thehelmet;

FIG. 10 is an exploded perspective view of a detent cap constructionmade in accordance with the present invention;

FIG. 11 is a perspective view of the detent cap construction of FIG. 10,illustrating the washer key and the detent cap in a locked position;

FIG. 12 is a perspective view of detent cap construction of FIG. 10,illustrating the washer key and the detent cap in an unlocked position;

FIG. 13 is an enlarged view of a side-pivot device made in accordancewith the present invention;

FIG. 14 is a perspective view of the side-pivot device of FIG. 13connected to the headgear strap of the present invention;

FIG. 15 is a detailed view of the side-pivot device of FIG. 13 in anopen (not in use) position;

FIG. 16 is a detailed view of the side-pivot device of FIG. 13 in aclosed (during use) position;

FIG. 17 is a perspective view of the side-pivot device of FIG. 13utilizing the front mounting hole of the headgear strap; and

FIG. 18 is a perspective view of the side-pivot device of FIG. 13utilizing the back mounting hole of the headgear strap.

It should be understood that the present invention is not limited to thepreferred embodiments illustrated.

DETAILED DESCRIPTION OF THE INVENTION

Referring generally to FIGS. 1-18, and upon review of this description,it will be appreciated that the apparatus of the present inventiongenerally may be embodied within numerous configurations.

FIG. 1 is a perspective view of the protective headgear assembly 10during use on a user's head. As shown in the preferred embodiment, theprotective headgear assembly 10 generally includes: a helmet 15 toprotect the user's head and eyes; a suspension system 12 to separate theuser's head from the helmet; a headgear strap 20; and a quick-releasemechanism 25. It will be appreciated that the helmet 15 can be any typeof protective body that protects a user's head and eyes, including,e.g., a face shield. It will also be appreciated that the helmet 15 ofthe protective headgear assembly 10 can be made of any hard materialthat resists impact. For example, among other hard materials, the helmet15 can be made of metal, plastic, or resin fiber. The headgear strap 20extends around the circumference of the user's head and provides for asecure and comfortable fit depending on the user's manual adjustments.The quick-release mechanism 25 preferably is integral to the headgearstrap 20 and lies at the back of the user's head during use.

Referring now to a preferred embodiment illustrated in FIGS. 2 and 3,the quick-release mechanism 25 comprises: (1) an adjusting knob 28 thatenables a user to adjust the length of the headgear strap 20; (2) ahousing 30 to define an internal cavity for receiving the headgear strap20; and (3) a gear system 32 for manipulation of the length of theheadgear strap 20. In this exemplary embodiment, the adjusting knob 28has a first end 28 a and a second end 28 b. The first end 28 a providesa component that the user can manipulate to adjust the length of theheadgear strap 20. The second end 28 b includes a cylindrical openingthat receives a cylindrical covering 29 of the gear system 32. Thecylindrical covering 29 is positioned on the exterior side of an outerhousing section 30 a. The second end 28 b also comprises ratchet teeth(not shown) that engage ratchet teeth 29 a of the cylindrical covering29. The outer housing section 30 a and an inner housing section 30 bjoin to form the housing 30, as shown in FIG. 3, and collectively definethe internal cavity for receiving the headgear strap 20. It will beappreciated that the housing 30 can be arc-shaped to fit securely aroundthe user's head. The quick-release mechanism 25 is preferably heldtogether by means of a rivet pin 26 that enters through the first end 28a of the adjusting knob 28. The pin 26 holds the knob 28 adjacent to alock gear 34 with a spring 31 interspersed between.

In the preferred embodiment, as illustrated in FIG. 2, the gear system32 of the quick-release mechanism 25 is comprised of a drive gear 33 andthe lock gear 34. The drive gear 33 comprises two integral sides 33 aand 33 b. A first side 33 a of the drive gear 33 preferably has radiallyinward projecting teeth which cooperate with radially outward projectingteeth of the lock gear 34. A second side 33 b of the drive gear 33preferably is a cog that engages two overlapping ends 20 a and 20 b ofthe headgear strap 20. The first end 20 a and second end 20 b of theheadgear strap each include lateral slots 21, 22 that have grippingteeth formed along the periphery of each slot. The quick-releasemechanism 25 further preferably comprises the spring 31 positionedwithin the cylindrical covering 29 which abuts a flange disposed on thecylindrical covering 29 on one end, and the lock gear 34 at the otherend. The spring 31 biases the lock gear 34 into engagement with theinward projecting teeth of the first side 33 a of the drive gear 33

The ratchet teeth 29 a of the cylindrical covering 29 engaged with theratchet teeth of the second side of the adjusting knob 28 b restrictmovement of the adjusting knob 28 by means of the spring 31. The lockgear 34 is rigidly connected to the adjusting knob 28. Accordingly,manual turning of the adjusting knob 28 by a user (see FIG. 3) causesthe gear system 32 to turn and engage the gripping teeth of the twolateral slots 21, 22 of the headgear strap 20, as shown in FIG. 4.Specifically, when the user turns the adjusting knob 28 clockwise, thefirst overlapping end 20 a and the second overlapping end 20 b of theheadgear strap 20 move toward one another laterally to decrease thecircumference of the headgear strap 20. Similarly, as shown in FIG. 5,when the user turns the adjusting knob 28 counterclockwise, the firstoverlapping end 20 a and the second overlapping end 20 b move away fromone another laterally to increase the circumference of the headgearstrap 20. The user must overcome sufficient torque provided by thespring 31 on the adjusting knob 28 in order to once again change theselected size of the headgear strap 20. The gripping teeth of the twolateral slots 21, 22 of the headgear strap 20 allow for incrementaltightening of the headgear strap 20. The user is accordingly able toadjust the headgear strap 20 so as to have a secure fit around his head.Once the user stops turning the adjusting knob 28 in either direction,the ratchet teeth 29 a of the cylindrical covering 29 engaged with theratchet teeth of the second side of the adjusting knob 28 b preventslateral movement of the overlapping ends 20 a, 20 b of the headgearstrap 20 and therefore locks the headgear strap 20 into a selected sizeand fit around the user's head.

Referring now to a preferred embodiment in FIGS. 6 and 7, the adjustingknob 28 of the quick-release mechanism 25 can further be manually pulledin a direction away from the housing 30 to disengage the gear system 32.When a user pulls the adjusting knob 28 in a direction away from theuser's head, the lock gear 34 is forced to separate from the drive gear33, causing the drive gear 33 to be able to freely rotate and unlock theheadgear strap 20 from the selected size. As a result, the firstoverlapping end 20 a and the second overlapping end 20 b of the headgearstrap 20 are able to move away from one another without any ratchetingof the adjusting knob 28. The user can simply pull the protectiveheadgear assembly 10 off of his head.

It will be appreciated that various attachment means can be employed toaffix the headgear strap 20 to the helmet 15. Referring now to apreferred embodiment in FIGS. 8-10, the protective headgear assembly 10comprises a multi-position stop construction 40 on a first side of thehelmet 15, and a detent cap construction 50 on a second side of thehelmet 15. As shown in FIGS. 8 and 9, the multi-position stopconstruction 40 comprises a knob 41, a washer 42, a washer key 43, and afive-position stop 44, all connected to the headgear strap 20 by meansof a pivot post 45. The five-pivot stop 44 comprises five adjustmentholes 44 a and pivots with the helmet 15. It will be appreciated thatany number of adjustment holes 44 a can be used in accordance with thepresent invention. The adjustment holes 44 a determine the position ofthe helmet 15 with respect to the suspension system 12 and headgearstrap 20. A pin 46 is affixed to the helmet in order to receive anadjustment hole 44 a. The helmet 15 can be positioned closer or fartherfrom the face of the user depending on the placement of the pin 46 intoan adjustment hole 44 a.

As shown in FIG. 10, the detent cap construction 50 on the second sideof the helmet 15 comprises a knob 51, a washer 52, a washer key 53, anda detent cap 54, all connected to the headgear strap 20 by means of apivot post 55. The detent cap 54 is preferably comprised of at least onenotch that matches and interacts with at least one notch on the washerkey 53. The washer key 53 and the detent cap 54 rotate relative to eachother. In order to lock the helmet 15 into an open position, the userlifts the helmet 15 until the washer key 53 and the detent cap 54 locktogether, as shown in FIG. 11. The user must overcome the forcenecessary to unlock the washer key 53 and the detent cap 54 by pullingthe helmet 15 down into a closed position, see FIG. 12.

Referring now to an alternative embodiment illustrated in FIGS. 13-18,it will be appreciated that the helmet 15 of the present invention canalso be attached to the headgear strap 20 by means of a side-pivotdevice 60, a pivot post 64, and a knob 65. As shown in FIGS. 15 and 16,the side-pivot device 60 comprises a pair of spring arms 60 a, 60 b thatinteract with a series of pins 61 on the headgear strap 20 to provide adented stop at either end of the pivot path. The spring arms 60 a, 60 brestrain the helmet 15 in either an open (not in use) position (see FIG.15), or a closed (in use) position (see FIG. 16) until adjusted by theuser. Further, as shown in FIGS. 17 and 18, in this alternativeembodiment, the headgear strap 20 can accommodate the side-pivot device60 in two different positions by means of a pair of mounting holes 62,63. The mounting holes 62, 63 are provided on the headgear strap 20 sothat the helmet 15 may be selectively positioned closer or farther fromthe front of the user's face. For example, FIG. 17 illustrates theside-pivot device 60 attached to the headgear strap 20 by means of thepivot post 64 received through the front mounting hole 62 of theheadgear strap 20, thereby positioning the helmet 15 farther in front ofthe operator's head than if the side-pivot device 60 was affixed to theback mounting hole 63 (see FIG. 18). The functionality of the side-pivotdevice 60 remains the same in either position.

It should be appreciated that merely preferred embodiments of theinvention have been described above. However, many modifications andvariations to the preferred embodiments will be apparent to thoseskilled in the art, which will be within the spirit and scope of theinvention. Therefore, the invention should not be limited to thedescribed embodiments. To ascertain the full scope of the invention, thefollowing claims should be referenced.

1. A quick-release system for changing the circumference of a headgearstrap comprising: a gear system rotatable about a central axiscomprising a drive gear and a lock gear, said lock gear interacting withsaid drive gear whereby said gear system operates in a first state andin a second state, said gear system configured such that in said firststate said lock gear is engaged with said drive gear and in said secondstate said lock gear is disengaged from said drive gear; a knob capableof movement along said central axis and operably connected to said lockgear; and a spring biasing said knob such that said gear system isbiased to said first state but allows said gear system to be moved tosaid second state through movement of said knob along said central axis.2. The quick-release system of claim 1 wherein said movement of saidknob along said central axis is substantially linear and away from saiddrive gear.
 3. The quick release system of claim 1 further comprising aratchet assembly operably connected to and fixed relative to said drivegear and provides resistance to rotation of said knob about said centralaxis and fixed substantially concentrically about said central axis. 4.The quick release system of claim 1 wherein rotation of said drive gearabout said central axis changes the circumference of the headgear strap.5. The quick release system of claim 1 wherein the spring is locatedbetween the lock gear and the ratchet system.
 6. The quick releasesystem of claim 1 further comprising a cylindrical portion of an outerhousing, said cylindrical portion having walls and a top defining acavity in which said gear system resides, said walls and top restrictingmovement of said lock gear between the first state and the second state.7. The quick release system of claim 1 wherein said drive gear, saidlock gear rotate about said central axis in response to rotation of saidknob when said system in the first state.
 8. A device for varying acircumference of a headgear strap, said device comprising: an adjustmentknob; and a housing comprising an inner housing section, an outerhousing section, and a gear mechanism, said outer housing sectiondefining a cavity containing said gear mechanism and capable ofconnection to said inner housing section to surround a portion of saidheadgear strap; wherein said gear mechanism is operable to repeatedlyengage and disengage from said headgear strap to vary and maintain thecircumference of the headgear strap.
 9. The device of claim 8 whereinthe adjustment knob is attached to said gear mechanism through anopening in said outer housing section.
 10. The device of claim 8 whereinthe cavity of said outer housing section is defined by a cylindricalportion extending away from said inner housing section.
 11. A headgearstrap attachment for fastening a piece of protective headgear to astrap, said attachment comprising: a pivot post and handle, said pivotpost extending through an opening in said piece of headgear andremovably coupling with said handle to retain said piece of headgear tosaid strap; and a side pivot device comprising a first adjustmentportion and a second adjustment portion; said first adjustment portionincluding a plurality of holes that interact with a first pin on saidpiece of headgear; and said second adjustment portion including a pairof spring arms that interact with a second pin on said strap to restrainthe piece of headgear in an open or closed position.
 12. The headgearstrap of claim 11 further comprising a plurality of mounting holes forfurther adjustment of the piece of headgear.
 13. A head strap for use inconjunction with a piece of protective headgear comprising: a quickrelease mechanism comprising: a gear system rotatable about a centralaxis comprising a drive gear and a lock gear, said lock gear interactingwith said drive gear whereby said gear system operates in a first stateand in a second state, said gear system configured such that in saidfirst state said lock gear is engaged with said drive gear and in saidsecond state said lock gear is disengaged from said drive gear; a knobcapable of movement along said central axis and operably connected tosaid lock gear; and a spring biasing said knob such that said gearsystem is biased to said first state but allows said gear system to bemoved to said second state through movement of said knob along saidcentral axis; and a strap attachment comprising: a pivot post andhandle, said pivot post extending through an opening in said piece ofheadgear and removably coupling with said handle to retain said piece ofheadgear to said strap; and a side pivot device comprising a firstadjustment portion and a second adjustment portion; said firstadjustment portion including a plurality of holes that interact with afirst pin on said piece of headgear; and said second adjustment portionincluding a pair of spring arms that interact with a second pin on saidstrap to restrain the piece of headgear in an open or closed position.